Single edge lit lighting module with bi-lobed light distribution

ABSTRACT

A single edge lit lighting module produces bi-lobed light distributions which provide targeted control of light output. The compact form factor of module embodiments having narrow width are particularly well-suited for use in linear lighting fixtures for suspended and downlighting configurations typically used to illuminate floors and/or ceilings. Embodiments of the single edge lit lighting module utilize reflectors in combination with light guides having volumetric light scattering properties and surface features to control peak intensities, output angles, and shapes of the two light output lobes. A variety of light distributions can be achieved including symmetrical distributions conventionally achieved by double edge lit modules. Further embodiments utilize selective alignment of light guide with reflector to achieve different light distributions thereby providing a fixture assembler with more design choices without need of additional components.

RELATED APPLICATIONS

This application is a continuation of and claims the benefit of non-provisional utility application Ser. No. 15/887,801 titled “Single Edge Lit Lighting Module Producing Tailored Light Distributions” filed Feb. 2, 2018 which itself claims the benefit of provisional patent application Ser. No. 62/453,588 titled “Single Edge Lit Lighting Module Producing Tailored Light Distributions” filed Feb. 2, 2017.

BACKGROUND

The invention relates to edge lit light fixtures which can be used in a variety of applications. In illumination applications it is often desired or required to control the light distribution in such a way as to output light from the fixture face with a greater proportion of light in a non-normal orientation. A batwing type distribution, named for the wing like appearance when shown on a polar plot of intensity vs. angle, is one such light distribution commonly used in down lighting to provide even floor and/or ceiling illumination with a minimal number of fixtures. For general area coverage, a symmetric batwing with two equal lobes along a given orientation axis is typical. For other applications such as targeting light distribution of a down light towards or away from a wall, fully or partially asymmetric light distributions are needed.

SUMMARY

A single edge lit lighting module is disclosed which produces tailored light distributions valuable in many illumination applications. The light distributions attainable using the invention include, but are not limited to, symmetric and asymmetric batwing distributions, asymmetric distributions for perimeter lighting and symmetric distributions. The invention's unique single edge lit construction provide the means for achieving desired non-lambertian light distributions without need for conventional two lit edges and within a compact form factor with narrow width, particularly well-suited for linear lighting fixtures. Various embodiments also provide means for adjusting light distributions dynamically to control light output characteristics by controlling the input signals to the LED board included in the assembly.

BRIEF DESCRIPTION OF FIGURES

The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

FIG. 1 is an isometric view of a light fixture with an embodiment lighting module.

FIG. 2 is an isometric view of a light guide illustrating key elements.

FIG. 3A and FIG. 3B combined are referred to as FIG. 3, a table listing some embodiments and their key characteristics.

FIG. 4 illustrates various embodiment surface features.

FIG. 5 is a photograph of a cross-section of the embodiment A light guide zoomed in on the surface features.

FIG. 6 shows cross-section views of light guide configuration of embodiments E and F.

FIG. 7 is a cross-section view of lighting module embodiment A1.

FIG. 8 is a polar plot showing cross-sectional angular light distribution of embodiment A1 lighting module.

FIG. 9 is a cross-section view of lighting module embodiment A2.

FIG. 10 is a polar plot showing cross-sectional angular light distribution of embodiment lighting module.

FIG. 11 is a polar plot relating to embodiment C and demonstrates effect of diffusion concentration on cross-sectional angular output.

FIG. 12 is a polar plot demonstrating the cross-sectional angular output of embodiment module D showing symmetric batwing light distribution.

FIG. 13 is a polar plot demonstrating the cross-sectional angular output of embodiment module D with different diffusion levels.

FIG. 14 is a polar plot demonstrating the cross-sectional angular output of embodiment module E1 with 12-6 light guide surface pattern on output face.

FIG. 15 is a polar plot demonstrating the cross-sectional angular output of embodiment module E2 with 12-6 light guide surface pattern on inner face.

FIG. 16 is a polar plot demonstrating the cross-sectional angular output of embodiment module F1 with 6-12 light guide surface pattern on output face.

FIG. 17 is a polar plot demonstrating the cross-sectional angular output of embodiment module F2 with 6-12 light guide surface pattern on inner face.

FIG. 18 is a polar plot illustrating the increased cross-sectional asymmetric angular output of embodiment module G having an etched light guide surface.

DETAILED DESCRIPTION

FIG. 1 is an isometric view of an embodiment light fixture with an embodiment lighting module. The lighting module is contained within a housing 100 supported by a wire hanger 101. Light is transmitted from the fixture through a light fixture output face 102. This could be the output face of the lighting module or an optically transmitting component positioned over the lighting module output face such as a cover lens or a glare control film.

FIG. 2 is an isometric view of a light guide illustrating key elements. Important to various embodiments are dimensions of width and height. Surface features and there pattern of arrangement on a face of the light guide are of importance in converting internal reflection within the light guide to output from the module at desired angular light distribution. Concentration of diffusing blend is an important variable in effecting light scattering properties that influence angular light distribution and uniformity of beam pattern. Volumetric light diffusion is produced by dispersed regions within the light guide having refractive index different than the bulk matrix material. Embodiments listed in the table of FIG. 3 include in the light guide formulation a specific commercially available diffusion resin, Plexiglas® Diffuse V045 blended into clear PMMA resin at the indicated weight percent within a range from zero to 20%. Alternative means in creating dispersed regions of differing refractive index from the light guide matrix material include dosing microbeads into the light guide resin formulation as well as forming second phase regions in situ during by fluid phase mixing of immiscible blends of polymers. In addition to refractive index, the quantity per volume, size, and shape of dispersed regions effect light scattering properties. In the case of immiscible blends formed by fluid phase mixing, the shape of second phase regions may be other that spherical, for example oblate paraboloid, thereby generating non-symmetric light scattering. Processes for fabricating light guides include extrusion and injection molding.

FIG. 3 is a table listing fabricated and tested light module embodiments and their key differentiating characteristics of light guide orientation, light guide height, light guide width, light guide surface feature geometry, bulk diffusion concentration, and reflector type.

FIG. 4 illustrates example embodiment surface patterns that have been developed to generate alternative beam output light distributions from light guide embodiments. These vary in both surface feature 9 size and shape as well as spacing of flat gaps between features and are labeled as SP1, SP2, SP3, SP4, and SP5. Alternative embodiments may utilize any variety of surface features that can be feasibly fabricated. Extrusion is a process in which lengths of light guide can be feasibly produced with patterns linear in the length dimension. In this case, prisms and lenticular designs can be readily produced. Asymmetric patterns including linear prisms with cross-sectional geometry of sawtooth triangles are also useful embodiments.

FIG. 5 is a photograph of a cross-section of the embodiment A light guide 3 zoomed in on the surface features 9. The features are fundamentally triangular prism lenticular with sides of the triangle being slightly concave.

FIG. 6 shows cross-section views of light guide configuration of embodiments E and F. The width of each light guide is 18 mm with 4.5 mm height. In embodiment E the first 6 mm of light guide surface adjacent to the input surface 4 has a flat surface and the next 12 mm of light guide surface 11 e has a lenticular pattern 10 e extending to the light guide opposing face 5.

FIG. 7 is a cross-section view of lighting module embodiment A1. The light source consists of individual light emitting diodes (LEDs) 1 mounted on an LED board 2 which is positioned adjacent to the light guide 3. Light emitted from the LEDs lenters the light guide through the light guide input face 4 and propagate through the light guide 3, partially internally reflecting from the faces of the light guide due to difference between the refractive index of the light guide and refractive difference of surrounding medium, typically air. Light guides typically comprise optically clear polymer or glass with high level of light transmission and refractive index greater than that of air which is 1.0. For example, polymethyl methacrylate (PMMA) is a common light guide material with refractive index of approximately 1.49. Some light does not internally reflect at the surface but rather escapes from the output face 6, typically with a light distribution centered at an angle less than 90 degrees from the output surface 6 and tilted away from the input face. Light that propagates through the light guide and exits through a light guide opposing face 5 is reflected back into the light guide by the reflector 8, the light guide opposing face effectively becoming in function a light guide input face. The reflector 8 wraps around both the light guide opposing face 5 and light guide inner face 7. Light that escapes the light guide 3 through the inner face 7 is reflected back into the light guide 3. For a reflector that is a specular reflector, light reflects back towards the light guide at the same angle from normal as light incident onto the reflector. Reflectors with a component of diffuse reflectance will produce more light scattering and a more dispersed light reflection.

FIG. 8 is a polar plot showing cross-sectional angular light distribution of embodiment A1 lighting module with surface features on the inner face of the light guide. The angular lobes are of a generally desirable bat wing type but the angular lobes are uneven and for most applications symmetric distribution would be preferred and specified.

FIG. 9 is a cross-section view of lighting module embodiment A2. This is the same as embodiment A1 except for the orientation of the light guide which has the surface features 9 positioned on the light guide output face 6 instead of on the light guide inner face 7.

FIG. 10 is a polar plot showing cross-sectional angular light distribution of embodiment lighting module A2 with surface features on the output face of the light guide. The angular light distribution is more asymmetric with light emitted less normal to the output surface than embodiment A1 which has the light guide orientation reversed.

FIG. 11 is a polar plot relates to embodiment C and demonstrates effect of diffusion concentration on cross-sectional angular output. Increasing diffusion concentration results in more overall output but less distinct bat wing lobes.

FIG. 12 is a polar plot demonstrating the cross-sectional angular output of embodiment module D showing symmetric batwing achieved with a light source input into only one face of a light guide. The batwing light distribution is desirable in many downlighting applications as it provides even illumination when projected onto flat surfaces such as floors and tables. To achieve this light distribution through a light guide with only one light source instead of the customary two provides reduced cost and a more narrow compact form factor.

FIG. 13 is a polar plot demonstrating the cross-sectional angular output of embodiment module D with different diffusion levels. The plots show the trends of increased luminous output and decreased angular asymmetry with increasing diffusion amount. The increased diffusion amount increases light scattering and the proportion of light which contacts a face of the light guide at an angle exceeding the critical angle of reflection thus exiting the light guide and not internally reflecting inside the light guide.

FIG. 14 and FIG. 15 are polar plots demonstrating the cross-sectional angular output of embodiment module E with the surface patterned face of the light guide as the output face (E1—FIG. 14) and inner face (E2—FIG. 15). In this embodiment the light guide has a pattern of surface lenticular area as illustrated as “Embodiment E” in FIG. 6. The light guide has a total width of 18 mm having on one 18 mm wide face an area of flat surface 6 mm wide and an area of lenticular pattern 12 mm wide. All plotted data is from testing done with the flat area of the patterned face adjacent to the input face of the light guide and the lenticular surface area positioned adjacent to face of the light guide opposing the input face. The plots show light distribution results with patterned lenticular face that are significantly different from and useful in a different manner than results from the full surface lenticular of embodiments A-D. In embodiments A-D the light distribution output in all cases is asymmetric with a larger lobe in the direction away from the light guide input face. In embodiment E the larger lobe of asymmetric output is in the direction toward the input light guide face. As diffusion level within the light guides of embodiment E is increased, the light distribution shifts more away from the input face of the light guide. With increasing diffusion level, there is a level where there is a net balance of surface feature and volumetric diffusion that results in a balanced bat wing type light distribution having lobes of light distribution that are largely symmetric and similar. For embodiment E this diffusion level appears by interpolation of FIG. 14 and FIG. 15 plots to be somewhere between 5% and 8%.

FIG. 16 and FIG. 17 are polar plots demonstrating the cross-sectional angular output of embodiment module F with the surface patterned face of the light guide as the output face (F1—FIG. 16) and inner face (F2—FIG. 17). In this embodiment the light guide has a pattern of surface lenticular area as illustrated as “Embodiment F” in FIG. 6. This light guide is similar to embodiment E but the patterned surface is changed to have 12 mm of flat surface area width and 6 mm of lenticular surface area as compared to 6 mm flat and 12 mm lenticular surface areas of embodiment E. As evidenced by the light distribution polar plots in FIG. 16 and FIG. 17, the degree of light output oriented toward the light guide input face is reduced in embodiment F vs. embodiment E, apparently due to the reduced area of lenticular on the patterned surface. This indicates that the percentage of surface pattern with light redirecting feature chosen can be used to adjust the light distribution and achieve targeted outcomes such as batwing light distribution.

FIG. 18 is a polar plot illustrating the increased cross-sectional asymmetric angular output of embodiment module G having an etched light guide surface. Compared to a non-etched surface the output is greater.

LIST OF NUMERICAL REFERENCES

1 LED

2 LED board

3 Light guide

4 Light guide input face

5 Light guide opposing face

6 Light guide output face

7 Light guide inner face

8 Reflector

9 Surface Features

10 Lenticular surface

11 Flat surface

12 Height

13 Width

100 Housing

101 Wire hanger

102 Light fixture output face 

What is claimed is:
 1. A lighting module comprising: a) a light guide comprising: i) an optically transmissive bulk material with dispersed regions of optically transmissive solid material within the bulk material wherein refractive index of the dispersed regions is different than the refractive index of the bulk matrix material, ii) a single input face, iii) an opposing face non-adjacent to the input face, iv) an inner face adjacent to the input face, v) an outer face adjacent to the input face; b) a light source inputting light into the single input face of the light guide; c) a first reflective surface positioned external of the light guide and proximate to the light guide inner face wherein light exiting the light guide inner face is reflected back into the light guide from the first reflective surface; d) a second reflective surface positioned external of the light guide and proximate to the light guide opposing face wherein light exiting the light guide opposing face is reflected from the second reflective surface; wherein the light output from the lighting module is a bi-lobed light distribution exiting from the outer face wherein one lobe of light is tilted towards the input face of the light guide and one lobe of light is tilted towards the opposing face of the light guide.
 2. A lighting module of claim 1 in which the light source is a linear array of light emitting diodes.
 3. A lighting module of claim 1 wherein the light guide is planar with width to height aspect ratio of less than
 4. 4. A lighting module of claim 1 in which the width of the light guide is less than 30 mm.
 5. A lighting module of claim 1 wherein the optically transmissive bulk material is either polymer or glass and has a refractive index greater than 1.0.
 6. A lighting module of claim 1 wherein the dispersed regions of optically transmissive solid material are comprised of microbeads.
 7. A lighting module of claim 6 wherein the microbeads comprise PMMA or acrylic.
 8. A lighting module of claim 1 wherein the light guide is further comprising surface features upon a face adjacent to the input face.
 9. A lighting module of claim 8 in which the light guide surface features adjusts the symmetry of the angular output versus a light guide equivalent in bulk material and dispersed regions without surface features.
 10. A lighting module of claim 8 wherein the light guide has surface features on the light guide outer face.
 11. A lighting module of claim 8 wherein the light guide has surface features on the light guide inner face.
 12. A lighting module of claim 8 in which the surface features comprise a full or partial geometric shape of a sphere, paraboloid, ellipsoid, polyhedron, or polyhedron frustum.
 13. A lighting module of claim 8 wherein the surface features re-direct light.
 14. A lighting module of claim 8 in which the surface features are arranged in a pattern.
 15. A lighting module of claim 14 in which the surface features comprise a lenticular pattern.
 16. A lighting module of claim 14 wherein the pattern includes flat areas of no surface features.
 17. A lighting module of claim 14 in which the surface feature pattern is comprised of a specific cross-sectional shape comprising a full or partial geometric form of a polygon, truncated polygon, concave polygon, convex polygon, parabola, ellipse, sphere, or arc.
 18. A lighting module of claim 8 wherein the presence of surface features on either inner face or outer face of the light guide is selectively chosen by orientation of the light guide with respect to the first reflective surface.
 19. The lighting module of claim 18 wherein when surface features are on the inner face of the light guide the light distribution is divided by the optical axis normal to the outer face into two portions of substantially equal integrated intensity over angle and when surface features are on the outer face of the light guide the light distribution is divided by the optical axis normal to the outer face into two portions of substantially unequal integrated intensity over angle.
 20. A lighting module of claim 1 wherein the light guide is fabricated using extrusion or injection molding techniques.
 21. A lighting module of claim 1 wherein the first and second reflective surfaces are regions of single reflector that wraps around 2 or more faces of the light guide.
 22. The lighting module of claim 1 wherein the first reflective surface or second reflective surface produce specular reflectance of incident light.
 23. The lighting module of claim 1 wherein the first reflective surface or second reflective surface produce diffuse reflectance of incident light.
 24. A lighting module of claim 1 wherein the two lobes of the bi-lobed light distribution are of substantially similar peak intensity.
 25. A lighting module of claim 1 wherein the two lobes of the bi-lobed light distribution are of substantially similar shape.
 26. A lighting module of claim 1 wherein the two lobes of the bi-lobed light distribution are of a substantially similar angle of tilt relative to the outer face of the lighting module.
 27. A lighting module of claim 1 wherein a lobe peak 1 has greater intensity than a lobe peak
 2. 28. A lighting module of claim 1 wherein lobe peak 1 has a greater angle of tilt with respect to the outer face than lobe peak
 2. 29. A lighting module of claim 1 wherein the bi-lobed light distribution has a local minimum point between the two lobed peaks.
 30. A lighting module of claim 1 wherein the local minimum point between the two lobe peaks is on or near the axis normal to the outer face.
 31. A lighting module of claim 1 wherein the local minimum point between the two lobe peaks is offset from the axis normal to the outer face.
 32. A lighting module of claim 1 wherein the light distribution is divided by the optical axis normal to the outer face into two portions of substantially equal integrated intensity over angle.
 33. A lighting module of claim 1 wherein the light distribution is divided by the optical axis normal to the outer face into two portions of substantially unequal integrated intensity over angle.
 34. A lighting module of claim 1 wherein the adjacent face is perpendicular to the input face.
 35. A lighting module of claim 1 wherein the adjacent face is perpendicular to the outer face.
 36. A lighting module of claim 1 further comprising an optically transmitting component positioned near the outer face wherein the optically transmitting component is the output face of a light fixture.
 37. A lighting module of claim 36 wherein the optically transmitting component is a cover lens.
 38. A lighting module of claim 36 wherein the optically transmitting component is a glare control film.
 39. A light fixture comprising the lighting module of claim 1 wherein the light fixture type is selected from the group consisting of linear, suspended, and downlight.
 40. A light fixture of claim 39 that is suspended by a wire from a ceiling.
 41. A light fixture of claim 39 that is used to illuminate a floor or a ceiling. 